Abstract:

This report consists of my six weeks experience of ARDIC (HIT Taxila Cantt). Whatever I have learned at
ARDIC is a part of this document. This report also consists of my experience that I have gained in that
time period. This report also represents the detail of my project. In addition to that we did some work on
FARO Arm, GeoMagix, Polyworks, FDM Titan, and Insight.
 Acknowledgment

I would like to thank, the Director General, ARDIC Heavy Industries Taxila (HIT) for giving me an
opportunity to work as an internee at this Research and Development center. The supervision and support
that they provided was really progressive and productive for us. The co-operation is much indeed
appreciated.

I would like to express my gratitude to my supervisor Sir Awais for sharing theoretical as well as practical
knowledge with us, his co-operation and assistance during the six weeks was very great indeed. The things
that I have learned and the tasks I have performed during my internship would have been very difficult
for us to accomplish without his guidance. Besides, this internship program makes me realize the value of
working together as a team and as a new experience in working environment. Also, great appreciation
goes to the rest of the staff that helped us time to time during the internship. Being the student of
Electrical Engineering this internship was a great opportunity for us to work in a research oriented
environment and was a unique learning experience.

Finally, I would like to show my great fullness to all the people and respondents who were available every
time to guide and teach us whatever I asked for them. I consider myself to be a lucky person to have an
opportunity to work with these people. They have been a source of strong inspiration for us and would
always be a part of whatever success I achieve.
Heavy Industries Taxila (HIT)
Heavy Industries Taxila (HIT) is a major defence, military contractor, engineering and Military
Corporation located in Taxila, Punjab. HIT is noted as being one of the largest defence contractor. HIT
promotes, markets, engineers, develops, and undertakes heavy engineering works for
Pakistan's military and for the civilian law enforcement agencies. It was founded in 1971 (47 years ago).

Production:
The main mission of HIT is to Manufacture, Rebuild, Upgrade & Develop Tanks, Tank Guns & APCs,
which includes following:

Main Battle Tanks:

 Al-Khalid/Al-Khalid I
 Al-Zarrar

Armoured Personnel Carriers (APC):

 APC Talha
 APC Saad
 AL-Sakb
 Al-Hamza
 Al-Hadeed
 Al-Qaswa

Armoured Cars:

 Mohafiz

Under Development:

 Al-Khalid II
 Burraq MRAP Vehicle
ARDIC:
Advanced Research, Development and Information Centre (ARDIC) is the main R&D (Research and
Development) center of HIT. IT serves HIT in all the fields of researching and development. Some of its
main services are:

1. Research, Develop and Integrate Advance Armour System, and Support Indigenous
Development/ production of high tech systems.
2. Deletion of Components and imported assemblies through R & D and reverse engineering with
in-house manufacture and in collaboration with local / foreign industrial setup.
3. Carry out R & D in the field of Advance Armour Systems.
4. To design and develop futuristic Armour system and technologies.
5. Carry out limited manufacturing to support the R & D efforts and also support the factories in
manufacturing of complex parts/systems.
6. Display of all HIT Products.

At ARDIC, Our main project was to research and design a test bench for AC brushless servo motors, used
in 3D printing machines.

SERVO MOTOR:
A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or
linear position, velocity and acceleration. It consists of a suitable motor coupled to a sensor for position
feedback

Main parts:

The servo motor is composed of three elements: the motor, the encoder and the driver. The driver
has the role of comparing the position command and the encoder position/speed information and
controlling the drive current. The servo motor must adjust the control system parameters to match the
rigidity of the mechanism and the load conditions.

AC brushless servo motor is made up of rotor and stator. Rotor is actually a permanent magnet while
stator consists of 24 coils wounded on the stator. A thermal heat sensor is also attached with coil.8 triplets
are made with 24 coils, and an optical encoder is attached inside the motor.
ENCODER:
An encoder is an electrical mechanical device that converts linear or rotary displacement into
digital or pulse signals. The most popular type of encoder is the optical encoder, which consists of a
rotating disk, a light source, and a photo detector (light sensor).

ROTARY ENCODERS:
A rotary encoder, also called a shaft encoder, is an electro-mechanical device that converts
the angular position or motion of a shaft or axle to analog or digital output signals

TYPES:

 Incremental Encoders
 Absolute Encoders

The Encoder used in AC servo motor is Incremental Encoder.

Incremental Encoder:
The output of an incremental encoder provides information about the motion of the shaft, which
typically is processed elsewhere into information such as position, speed and distance.

An incremental encoder will immediately report changes in position, which is an essential

capability in some applications. However, it does not report or keep track of absolute position. As a result,
the mechanical system monitored by an incremental encoder may have to be moved to a fixed reference
point to initialize the position measurement.

Working Principle:
An incremental encoder is a linear or rotary electromechanical device that has two output
signals, A and B, which issue pulses when the encoder is moved. Some encoders have an additional output
signal, typically designated "index" or Z, which indicates the encoder is located at a particular reference
position. Also, some encoders provide a status output that indicates internal fault conditions such as a
bearing failure or sensor malfunction.

Two square waves in quadrature. The direction of motion is indicated by the sign of the A-B phase angle
which, in this case, is negative because A trails B.
Conceptual drawing of a rotary incremental encoder's position sensing mechanism, with the
corresponding logic states of the A/B signals shown above.
The A and B output pulses are quadrature-encoded, meaning that when pulses are being issued,
the duty cycle of each pulse is 50% (i.e., the waveform is a square wave) and there is a 90 degree phase
difference between A and B. At any particular time, this 90° phase angle will positive or negative
depending on the encoder's direction of movement. In the case of a rotary encoder, the phase angle is
+90° for clockwise rotation and -90° for counter-clockwise rotation, or vice versa, depending on the
device design.
The frequency of the pulses on the A or B output is directly proportional to the encoder's velocity
(rate of position change); higher frequencies indicate rapid movement, whereas lower frequencies
indicate slower speeds. Static, unchanging signal levels are output on A and B when the encoder is
motionless. In the case of a rotary encoder, the frequency indicates the speed of the encoder's shaft
rotation, and in linear encoders the frequency indicates the speed of linear travel.
Position tracking:
Incremental encoders report position changes without being prompted to do so, and they convey
this information at data rates which are orders of magnitude faster than those of most types of absolute
encoders. The resulting, very low data latency of an incremental encoder allows it to be used to monitor
the position of a high-speed mechanism in real time (a capability lacking in most types of absolute
encoders). Because of this, incremental encoders are commonly used in applications that require precise
measurement of position and velocity.
Unlike absolute encoders, an incremental encoder does not keep track of, nor do its outputs indicate the
current encoder position; it only reports incremental changes in position . Consequently, to determine the
encoder's position at any particular moment, it is necessary to provide external electronics which will
"track" the position. This external circuitry, which is known as an incremental encoder interface, tracks
an encoder's position by counting the pulse edges emitted from the encoder's A and B outputs. As it
receives each edge, the encoder interface takes into account the phase relationship between A and B and,
depending on the sign of the phase angle, will either count up or down. The current "counts" value stored
in the counter indicates the distance traveled since tracking began.
To be useful, the encoder counts (maintained by the encoder interface) must be correlated to a reference
position in the mechanical system to which the encoder is attached. This is commonly done by "homing"
the system, which consists of moving the mechanical system (and encoder) until it aligns with a reference
position, and then jamming the associated, correlated counts into the encoder interface's counter.

Quadrature decoder

A quadrature decoder converts the A and B signals from an incremental encoder into direction and count
enable signals, which are used to control a synchronous up/down counter

Incremental encoder interfaces commonly use a quadrature decoder to convert the A and B
signals into the direction and count enable (clock enable) signals needed for controlling a
synchronous, bidirectional (up- and down-counting) binary counter.
In any two consecutive AB samples, the logic state of A or B may change or both states may remain
unchanged, but in normal operation the A and B states will never both change. When neither A nor B
changes, the quadrature decoder assumes the encoder has not moved and so it negates its count
enable output, thereby causing the counts to remain unchanged. When just A or B changes state, the
quadrature decoder assumes the encoder has moved one increment of its measurement resolution and,
accordingly, it may assert its count enable output to allow the counts to change, and assert or negate
its direction output to cause the counts to increment or decrement (or vice versa).
 If the A and B states both change simultaneously, the clock decoder has no way of determining how
many increments, or in what direction the encoder has moved. This can happen if the encoder speed
is too fast for the quadrature decoder to process (i.e., the rate of AB state changes exceeds the
quadrature decoder's sampling rate) or if the A or B signal is noisy. In most encoder applications this
is a catastrophic event because the counter no longer provides an accurate indication of encoder
position. Consequently, many quadrature decoders output an additional error signal which is
asserted when the A and B states change simultaneously. Due to the severity and time-sensitive
nature of this condition, the error signal is often connected to an interrupt request.

Controlling of servo motor:

Servo motor driver allows for easy operation and control of the servo motors. Four control modes
are available:
 Position
 Speed
 Torque
 Tension Control
The driver provides automatic tuning allowing for optimal performance without manual adjustments.

 Built-in Protective Functions

 Pulse Input Type
 Single-Phase 100-115 VAC

PWM BRUSHLESS AC SERVO DRIVE:

The BE25A20 PWM servo drive is designed to drive brushless DC motors at a high switching frequency. A
single red/green LED indicates operating status. The drive is fully protected against over-voltage, under
voltage, over-current, over-heating and short-circuits across motor, ground and power leads.
Furthermore, the drive can interface with digital controllers or be used stand-alone, and requires only a
single unregulated DC power supply. Loop gain, current limit, input gain and offset can be adjusted using
14turn potentiometers. The offset adjusting potentiometer can also be used as an on-board input signal
for testing purposes. This drive can use quadrature encoder inputs for velocity control.

Power Range :
Peak Current 25 A

Continuous Current 12.5 A

Supply Voltage 40 - 190 VDC

Features of PWM servo drive:

 Four Quadrant Regenerative Operation
 DIP Switch Selectable Modes
 Adjustable Current Limits
 Differential Input Command
 On-Board Test Potentiometer
 Offset Adjustment Potentiometer
 Adjustable Input Gain
  Selectable 120/60 Hall Commutation Phasing
 DIP Switch Selectable Tuning
 Encoder Velocity Mode
 Drive Status LED
 Velocity Monitor Outputs

MODES OF OPERATION:
 Current Open Loop
 Encoder Velocity
 Tachometer Velocity

Current Open Loop:

In an open-loop controller, also called a non-feedback controller, the control action from the controller is
independent of the "process output", which is the process variable that is being controlled. It does not
use feedback to determine if its output has achieved the desired goal of the input command or process "set
point".

Encoder Velocity:
The most common use for encoders is to measure angular or linear distance, but encoders can also be
used to perform speed or velocity measurements. This is possible because there is a linear relationship
between an encoder’s pulse frequency and its rotational velocity. In other words, as the encoder rotates
faster, the pulse frequency increases at the same rate.
Tachometer Velocity:
A servo drive configured for Velocity Mode turns the motor at a velocity that is proportional to the
command. Small commands will generate small velocities and large commands will generate large
velocities. Velocity Mode requires the use of a velocity feedback device, such as an encoder, resolver,
tachometer, or Hall Sensors.

PWM Drive Specifications:

Connectors Types & Specifications:
 MODES:

Potentiometer :

Block Diagram:

Power supply Shunt Regulator Filter Card

Drive

Motor
This the block diagram of setup to control and test all the features of AC brushless motor.